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Go Back   Bimmerfest - BMW Forums > BMW Model Discussions > 5 Series > E39 (1997 - 2003)

E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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  #1  
Old 01-06-2013, 12:32 PM
Takechan Takechan is offline
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Location: Scandinavia
 
Join Date: Mar 2009
Posts: 244
Mein Auto: BMW E39 520i (M52B25)
Bosch Alternator Rebuild Success!

Hi,

Inspired by cn90's Bosch Alternator DIY and continuing on my post in that thread, I've finished rebuilding my old Bosch alternator - what an improvement. My swapped engine came with a Valeo 80A which ran 13.6-14.2V at idle. When I installed my rebuilt Bosch it now idles at 14.6-14.8V!

I had originally planned to rebuild my Valeo so I could follow the YouTube DIY:

Valeo - Part I


Valeo - Part II


However, the parts for the Valeo were extremely difficult to source, so I opted for a rebuild of my old Bosch instead.

My alternator (RealOEM):

Brand: Bosch 80A
Production date: 43/96
Bosch part number: 1 740 624
BMW part number: 0 123 315 013

I bought my non-OEM parts from lima-shop.de (German):

1 x Ball Bearing 6304 EHSR 2RS1 c3 - 17x52x17 (14.95 EUR / 19.55 USD)
1 x Ball Bearing 6203 2RS1 c3 - 17x40x12 mm (5,95 EUR / 7.78 USD)
1 x Regulator 14,1V 1197311545 Bosch BMW alternator 545-1980 (42,95 EUR / 56.18 USD)
1 x Slip ring d 16mm for Bosch Alternator (8,95 EUR / 11.70 USD)
1 x Shipping (13,90 EUR / 18.18 USD)

Sub-total: 86.70 EUR / 113.41 USD
Pay-pal fee (3.85%): 3.34 EUR / 4.37 USD
Total: 90,04 EUR / 117.79 USD



No special tools were used, but it was a PITA to remove the bearings. The one on the slip ring can be removed with a bearing removal tool, but the front bearing was inaccessible so I had to resort to proper violence...
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Last edited by Takechan; 01-06-2013 at 12:34 PM.
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  #2  
Old 01-06-2013, 12:46 PM
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bluebee bluebee is offline
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Location: San Jose, California
 
Join Date: Mar 2008
Posts: 20,315
Mein Auto: 02 BMW 525i M54 auto 130K
Ooooh. An instant classic for the bestlinks!
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Each repair should invariably add to our knowledge base by the process of inexorable incrementalism.
Your job, in return, is to read the suggested threads, where the best people will always add value to those threads, either by pictures or by descriptions, so the next person with the same problem stands on your shoulders.
See also: E39 Bestlinks & How to easily find what you need
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  #3  
Old 01-07-2013, 02:13 AM
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moots moots is offline
wat's dat noise
Location: Malaysia
 
Join Date: Apr 2005
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Mein Auto: '04 525i
woahhh...i was thinking the slip rings are part of the winding ie as 1 unit.....

thanks.great info and pics.....now where's my credit card......
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Old 01-07-2013, 08:18 AM
cn90 cn90 is offline
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I thought the front bearing is easy to remove, why the "violence"?
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Old 01-07-2013, 09:24 AM
cn90 cn90 is offline
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Mein Auto: 1998 528i 5-sp 140K+
Below is a very good DIY on Bosch alternator:
- Rear bearing: gear puller
- Front Bearing: remove the plate holding the bearing, if you have a press tool ---> great, if not use the large gear puller + socket.

http://www.oichan.org/mods/alter/alter2.htm


Some people find that if you gently lift the bearing's seal, apply new grease, then no need to replace the bearing:

http://forum.roadfly.com/threads/130...ternator-issue
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  #6  
Old 01-07-2013, 12:03 PM
pleiades pleiades is offline
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Quote:
Originally Posted by cn90 View Post
I thought the front bearing is easy to remove, why the "violence"?
You really need shop press to do it on the Bosch units. Although the spindle can be tapped out of the bearing with a small sledge (and something in between to prevent the spindle tip from mushrooming).

BTW..... if you can expose the large bearing well enough to pop a seal off and add grease, I cannot understand why you wouldn't simply just go ahead and replace the bearing outright?
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  #7  
Old 01-07-2013, 01:42 PM
Takechan Takechan is offline
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Location: Scandinavia
 
Join Date: Mar 2009
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Mein Auto: BMW E39 520i (M52B25)
cn90, excellent DIY!

Unfortunately I don't have a press, so I had to use a hammer... the bearing was stuck on the spindle, so the casing wouldn't come off. I wasn't afraid to whack it a bit seeing as it was a "spare".
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Old 08-15-2013, 09:34 PM
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bluebee bluebee is offline
Seek to understand,^Value
Location: San Jose, California
 
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Mein Auto: 02 BMW 525i M54 auto 130K
For the record, this German web page for Bosch alternator parts shows a huge list of cross references for Bosch alternator rebuilding parts such as...
__________________
Each repair should invariably add to our knowledge base by the process of inexorable incrementalism.
Your job, in return, is to read the suggested threads, where the best people will always add value to those threads, either by pictures or by descriptions, so the next person with the same problem stands on your shoulders.
See also: E39 Bestlinks & How to easily find what you need
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